HONDA IGX440 User Manual [en, es, fr]

INTRODUCTION

Thank you for purchasing a Honda engine. We want to help you to get the best results from your new engine and to operate it safely. This manual contains information on how to do that; please read it carefully before operating the engine. If a problem should arise, or if you have any questions about your engine, consult an authorized Honda servicing dealer.
All information in this publication is based on the latest product information available at the time of printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the engine and should remain with the engine if resold.
Review the instructions provided with the equipment powered by this engine for any additional information regarding engine startup, shutdown, operation, adjustments or any special maintenance instructions.
United States, Puerto Rico, and U.S. Virgin Islands: We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer.

SAFETY MESSAGES

OWNER’S MANUAL
MANUEL DE L’UTILISATEUR
iGX440
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects
or other reproductive harm.
ENGLISHFRANÇAISESPAÑOL
Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the engine. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury.
DAMAGE PREVENTION MESSAGES
You will also see other important messages that are preceded by the word NOTICE.
This word means:
Your engine or other property can be damaged if you don’t follow instructions.
The purpose of these messages is to help prevent damage to your engine, other property, or the environment.
2005 - 2006 Honda Motor Co., Ltd. All Rights Reserved

CONTENTS

.......................INTRODUCTION .1
................SAFETY MESSAGES .1
..........SAFETY INFORMATION .2
COMPONENT & CONTROL
................................LOCATION .2
................................FEATURES .3
BEFORE OPERATION
....................................CHECKS .3
..............................OPERATION .4
SAFE OPERATING
.....................PRECAUTIONS .4
THE IMPORTANCE OF
....................MAINTENANCE .6
MAINTENANCE
............................SCHEDULE .7
...........................REFUELING .7
...........................ENGINE OIL .8
............Recommended Oil .8
..................Oil Level Check .8
.........................Oil Change .9
........................AIR CLEANER .9
..........................Inspection .9
............................Cleaning .9
..................SEDIMENT CUP .10
..........................Cleaning .10
.....SAFETY LABEL LOCATION .2
......STARTING THE ENGINE .4
......STOPPING THE ENGINE .6
.....SETTING ENGINE SPEED .6
.....SERVICING YOUR ENGINE .6
......MAINTENANCE SAFETY .6
.......SAFETY PRECAUTIONS .6
......................SPARK PLUG .11
.............SPARK ARRESTER .11
....................................FUSE .12
HELPFUL TIPS &
......................SUGGESTIONS .13
...STORING YOUR ENGINE .13
................TRANSPORTING .14
TAKING CARE OF
....UNEXPECTED PROBLEMS .14
..TECHNICAL INFORMATION .15
.....Serial Number Location .15
Battery Connections for
....................Electric Starter .16
Carburetor Modifications for
.....High Altitude Operation .16
Emission Control System
.........................Information .17
..............................Air Index .17
.....................Specifications .18
........Tuneup Specifications .18
Quick Reference
.........................Information .19
Muffler Deflector Kit
..........................Installation .19
................Wiring Diagrams .19
.CONSUMER INFORMATION .23
Distributor/Dealer Locator
.........................Information .23
Customer Service
.........................Information .23
37Z3S603 00X37-Z3S-6030
GX440IU
ENGLISH
1

COMPONENT & CONTROL LOCATIONSAFETY INFORMATION

Understand the operation of all controls and learn how to stop the engine quickly in case of emergency. Make sure the operator receives adequate instruction before operating the equipment. Do not allow children to operate the engine. Keep children and pets away from the area of operation. Your engine’s exhaust contains poisonous carbon monoxide. Do not run the engine without adequate ventilation, and never run the engine indoors. The engine and exhaust become very hot during operation. Keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running.

SAFETY LABEL LOCATION

(STANDARD TYPES)
This label warns you of potential hazards that can cause serious injury. Read it carefully. If the label comes off or becomes hard to read, contact your Honda dealer for replacement.
STANDARD TYPES
MUFFLER
LED
ECM
IGNITION COIL
FUEL TANK
SPARK PLUG (Inside ignition coil)
OIL FILLER CAP/DIPSTICK
FUEL FILLER CAP
AIR CLEANER
RECOIL STARTER (applicable types)
STARTER GRIP (applicable types)
OIL EXTENSION (applicable types)
ELECTRIC STARTER (applicable types)
FUSE (applicable types)
OIL DRAIN PLUG
(LOW PROFILE TYPES)
These labels are packed in the box.
Gasoline is highly flammable and explosive. Turn engine off and let cool before refueling.
The engine emits toxic poisonous carbon monoxide gas. Do not run in an enclosed area.
Read Owner’s Manual before operation.
For Canadian types only: French label comes with the engine.
ELECTRIC STARTER TYPES
MANUAL START LEVER
RECOIL STARTER TYPES
CHOKE LEVER
FUEL VALVE LEVER (applicable types)
LOW PROFILE TYPES
MUFFLER (applicable types)
OIL FILLER CAP/DIPSTICK
ELECTRIC STARTER (applicable types)
RECOIL STARTER (applicable types)
THROTTLE CONTROL (applicable types)
ENGINE SWITCH (applicable types)
THROTTLE CONTROL (applicable types)
ENGINE SWITCH (applicable types)
STARTER GRIP (applicable types)
AIR CLEANERIGNITION COIL
2
ENGLISH
ELECTRIC STARTER TYPES
RECOIL STARTER TYPES
CHOKE LEVERMANUAL START LEVER

BEFORE OPERATION CHECKS

IS YOUR ENGINE READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.
Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.
Always perform a pre-operation inspection before each operation, and correct any problem.
Before beginning your pre-operation checks, be sure the engine is level and the engine switch is in the OFF position.
Always check the following items before you start the engine:
Check the General Condition of the Engine

FEATURES

OIL ALERT
‘‘Oil Alert is a registered trademark in the United States’’
The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will either shut off the engine or issue a warning. Refer to the instructions provided by the equipment manufacturer.
If the ECM is set to stop the engine:
Electric start
Recoil start The engine stops.
If the ECM is set to continue engine operation:
Electric start
Recoil start The engine continues to operate.
SYSTEM
Engine type Oil Alert action
The LED on the ECM blinks twice. The engine stops. The engine will not restart.
The engine will not restart.
Engine type Oil Alert action
The LED on the ECM blinks twice. The engine continues to operate. The engine will not restart.
The engine will not restart.
Look around and underneath the engine for signs of oil or
1. gasoline leaks.
Remove any excessive dirt or debris, especially around the
2. muffler and recoil starter.
Look for signs of damage.
3.
Check that all shields and covers are in place, and all nuts, bolts,
4. and screws are tightened.
Check the Engine
Check the fuel level (see page ). Starting with a full tank will
1. help to eliminate or reduce operating interruptions for refueling.
Check the engine oil level (see page ). Running the engine
2. with a low oil level can cause engine damage.
If the oil level in the crankcase falls below a safe limit, the Oil Alert system will either shut off the engine or issue a warning. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup.
Check the air filter element (see page ). A dirty air filter
3. element will restrict air flow to the carburetor, reducing engine performance.
7
8
9, 10
If the engine stops and/or will not restart, check the oil level (see page ) before troubleshooting in other areas.
8
If you continue to operate the engine after the Oil Alert system has been activated, you can damage the engine.
Check the equipment powered by this engine.
4.
Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup.
ENGLISH
3

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the engine for the first time, please review the
SAFETY INFORMATION OPERATION CHECKS
Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you.
Avoid any areas or actions that expose you to carbon monoxide.
Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed with engine startup, shutdown or operation.

STARTING THE ENGINE

ELECTRIC STARTER TYPES:
Turn the engine switch to the
1. START position, and hold it there until the engine starts.
section on page and the
on page .
3
2
BEFORE
If the electric starter will not operate: (with recoil starter types)
Push the manual start lever.
1.
STANDARD TYPES
MANUAL START LEVER
PPuusshh
LOW PROFILE TYPES
CLOSE
MANUAL START LEVER
PPuusshh
The engine switch opens the fuel valve and operates the automatic choke.
Some engine applications do not include the engine­mounted engine switch shown here. Refer to the instructions provided by the equipment manufacturer.
If the engine fails to start within 5 seconds, release the engine switch, and wait at least 10 seconds before operating the starter again.
Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.
When the engine starts, release the engine switch, allowing it to return to the ON position.
ENGINE SWITCH
OONN
SSTTAARRTT
Do not move the manual start lever after the engine starts.
Turn the engine switch to the ON position.
2.
ON
ENGINE SWITCH
Pull the starter grip lightly until you feel resistance, then pull
3. briskly in the direction of the arrow as shown below. Return the starter grip gently.
STARTER GRIP
Warm up the engine for 2 or 3
2. minutes.
4
Directiontopull
Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.
4.
Warm up the engine for 2 or 3 minutes.
ENGLISH
RECOIL STARTER TYPES:
1.
Move the fuel valve lever (applicable types) to the ON position.
4.
Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown below. Return the starter grip gently.
FUEL VALVE LEVER (applicable types)
ON
OONN
2.
To start a cold engine, move the choke lever to the CLOSED position.
Some engine types use a remote-mounted choke lever. Refer to the instructions provided by the equipment manufacturer.
STANDARD TYPES
CLOSE
CCLLOOSSEE
Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.
STARTER GRIP
Directiontopull
Warm up the engine for 2 or 3 minutes.
5.
If the choke lever was moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up.
STANDARD TYPES
CHOKE LEVER
LOW PROFILE TYPES
CLOSE
CCLLOOSSEE
CHOKE LEVER
To restart a warm engine, leave the choke lever in the OPEN position.
3.
Turn the engine switch to the ON position.
Some engine types use a remote-mounted engine switch. Refer to the instructions provided by the equipment manufacturer.
ON
OOPPEENN
CHOKE LEVER
LOW PROFILE TYPES
CHOKE LEVER
OOPPEENN
ENGINE SWITCH
ENGLISH
5

STOPPING THE ENGINE

SERVICING YOUR ENGINE

To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure.
1.
Move the throttle control to the MIN. position.
Some engine types use a remote-mounted throttle control. Refer to the instructions provided by the equipment manufacturer.
2.
Turn the engine switch to the OFF position.
Some engine types use a remote-mounted engine switch. Refer to the instructions provided by the equipment manufacturer.
MMIINN
OOFFFF
THROTTLE CONTROL
ENGINE SWITCH

THE IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe, economical and trouble­free operation. It will also help reduce pollution.
Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.
Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.
To help you properly care for your engine, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If you operate your engine under severe conditions, such as sustained high-load or high-temperature operation, or use in unusually wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.
3.
Move the fuel valve lever (applicable types) to the OFF position.
FUEL VALVE LEVER (applicable types)
OOFFFF
OFF

SETTING ENGINE SPEED

Adjust the throttle control for the desired engine speed.
Some engine types use a remote-mounted throttle control, rather than the engine-mounted throttle control shown here. Refer to the instructions provided by the equipment manufacturer.
For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine.
MMAAXXMMIINN
THROTTLE CONTROL
6
Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are ‘‘certified’’ to EPA standards.

MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.
Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.
Always follow the procedures and precautions in this owner’s manual.

SAFETY PRECAUTIONS

Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you operate the engine.
Burns from hot parts.
Let the engine and exhaust system cool before touching.
Injury from moving parts.
Do not run the engine unless instructed to do so. Read the instructions before you begin, and make sure you have the tools and skills required. To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts.
Remember that an authorized Honda servicing dealer knows your engine best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new genuine Honda parts or their equivalents for repair and replacement.
ENGLISH

MAINTENANCE SCHEDULE

REFUELING (LOW PROFILE TYPES)
STANDARD TYPES
REGULAR SERVICE PERIOD (3)
Perform at every indicated month or operating hour interval,
whichever comes first. ITEM Engine oil
Air cleaner
Sediment cup Spark plug
Spark arrester Valve clearance
Timing belt
Combustion chamber Fuel tank & filter Fuel tube
Check level Change Check Clean Replace Clean Check-adjust Replace Clean Check-adjust
Check
Clean
Clean
Check
First
Each
Use
Every 6
Month
Months
or
20 Hrs
100 Hrs
After every 500 Hrs. (2) (4)
After every 500 Hrs. (2)
Every 2 years
(Replace if necessary) (2)
Follow the equipment manufacturers recommendation for
Every
2 Years
Year
Page
or
or
or
500 Hrs
300 Hrs
refueling.
to
REFUELING (STANDARD TYPES)

Recommended Fuel

Refer
Every
Unleaded gasoline
(1)
U.S.
8 9 9 9
This engine is certified to operate on unleaded gasoline with a
Except U.S.
Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 86 or higher
pump octane rating of 86 or higher (a research octane rating of 91
10
or higher).
11
Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the
11
engine inside a building where gasoline fumes may reach flames
(2)
(2)
Shop
manual
Shop
manual
Shop
manual
Shop
manual
Shop
manual
or sparks. You may use regular unleaded gasoline containing no more than 10% Ethanol (E10) or 5% Methanol by volume. In addition, Methanol must contain cosolvents and corrosion inhibitors. Use of fuels with content of Ethanol or Methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of Ethanol or Methanol greater than shown above are not covered under warranty.
LOW PROFILE TYPES
Every 6
REGULAR SERVICE PERIOD (3)
Perform at every
indicated month or
operating hour interval,
whichever comes first. ITEM Engine oil
Air cleaner
Sediment cup Spark plug
Spark arrester
Valve clearance
Timing belt
Combustion chamber Fuel tube
(1)
Service more frequently when used in dusty areas.
(2)
These items should be serviced by your Honda servicing
Check level Change Check Clean Replace Clean Check-adjust Replace Check-Clean
Check-adjust
Check
Clean
Check
Each
Months
Month
Use
or
50 Hrs
20 Hrs
After every 500 Hrs. (2) (4)
After every 500 Hrs. (2)
Every 2 years
(Replace if necessary) (2)
or
(1)
Every 3
First
Months
or
100 Hrs
Every
Year
or
300 Hrs
dealer, unless you have the proper tools and are mechanically
proficient. Refer to the Honda shop manual for service
procedures.
(3)
For commercial use, log hours of operation to determine
proper maintenance intervals.
Check that there is no crack and abnormal wear-out in the belt,
(4)
and replace if it is abnormal.
(2)
Refer
to
Page
8
9 10 10
10 11
11
Shop
manual
Shop
manual
Shop
manual
Shop
manual
Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling.
Stop engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately.
Fuel can damage paint and some types of plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under the
Distributor’s Limited Warranty.
Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.
1.
With the engine stopped and on a level surface, remove the fuel filler cap and check the fuel level. Refill the tank if the fuel level is low.
2.
Add fuel to the bottom of the fuel level limit of the fuel tank. Do not overfill. Wipe up spilled fuel before starting the engine.
FUEL TANK TOP
25 mm (1 inch)
MAXIMUM FUEL LEVEL
Failure to follow this maintenance schedule could result in non­warrantable failures.
ENGLISH
7
Refuel carefully to avoid spilling fuel. Do not fill the fuel tank completely. It may be necessary to lower the fuel level depending on operating conditions. After refueling, screw the fuel filler cap back on until it clicks.

Oil Level Check

Check the engine oil level with the engine stopped and in a level position.
Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.
Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately.

ENGINE OIL

Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil.

Recommended Oil

Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ or later (or equivalent). Always check the API service label on the oil container to be sure it includes the letters SJ or later (or
AMBIENT TEMPERATURE
equivalent).
SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.
1.
Remove the oil filler cap/dipstick and wipe it clean.
2.
Insert the oil filler cap/dipstick into the oil filler neck as shown, but do not push it in, then remove it to check the oil level.
3.
If the oil level is below the upper limit mark on the dipstick, fill with the recommended oil (see page ) to the upper limit mark.
9
Do not overfill.
4.
Reinstall and tighten the oil filler cap/dipstick.
DIPSTICK
UPPER LIMIT
OIL FILLER CAP
Running the engine with a low oil level can cause engine damage.
The Oil Alert system will stop the engine or issue a warning before the oil level falls below a safe limit. Refer to the instructions provided by the equipment manufacturer.
8
ENGLISH

Oil Change AIR CLEANER

Drain the used oil when the engine is warm. Warm oil drains quickly and completely.
1.
Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick, oil drain plug and washer.
2.
Allow the used oil to drain completely, then reinstall the oil drain plug and new washer, and tighten the oil drain plug securely.
Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash, pour it on the ground, or pour it down a drain.
With the engine in a level position, fill to the upper limit mark on
3. the dipstick with the recommended oil (see page ).
8
Running the engine with a low oil level can cause engine damage.
Install the oil filler cap/dipstick and push it in securely.
4.
OIL FILLER CAP
DIPSTICK
UPPER LIMIT
A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean or replace the air filter more often than specified in the MAINTENANCE SCHEDULE.
Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the
Distributor’s Limited
Warranty.
Inspection (standard types)
Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements.
Cleaning (standard types)
Remove the wing nut from
1.
NUT
the air cleaner cover, and remove the cover.
Remove the wing nut from
2. the air filter, and remove the
AIR CLEANER COVER
WING NUT
filter.
PAPER FILTER
Remove the foam filter from
3.
ELEMENT
the paper filter.
FOAM FILTER
Inspect both air filter
4.
ELEMENT
elements, and replace them if they are damaged. Always
GASKET
replace the paper air filter element at the scheduled interval (see page ).
7
DRAIN PLUG
WASHER
Clean the filter elements if they are to be reused.
5.
Paper filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 207 kPa(2.1kgf/cm
, 30 psi)] through the filter element from the inside.
Never try to brush off dirt; brushing will force dirt into the fibers.
Foam filter element: Clean in warm soapy water, rinse, and allow to dry thoroughly. Or clean in nonflammable solvent and allow to dry. Dip the filter element in clean engine oil, then squeeze out all excess oil. The engine will smoke when started if too much oil is left in the foam.
Dry
ENGLISH
Soak Squeeze SqueezeOil
9
6.
Wipe dirt from the inside of the air cleaner case and cover using a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor.
Place the foam filter element over the paper element, and
7. reinstall the assembled air filter. Be sure the gasket is in place beneath the air filter. Tighten the air filter wing nut securely.
8.
Install the air cleaner cover, and tighten the nut securely.
5.
Clean the foam element if it is to be reused.
Clean in warm soapy water, rinse, and allow to dry thoroughly. Or clean in nonflammable solvent and allow to dry. Dip the filter element in clean engine oil, then squeeze out all excess oil. The engine will smoke when started if too much oil is left in the foam.
Inspection (low profile types)
Do not blow with compressed air or brush the paper filter element.
Remove the air cleaner cover and inspect the filter elements. Visually inspect the filter elements. Clean the foam filter element or replace the dirty paper filter element. Always replace damaged filter elements.
Cleaning (low profile types)
1.
Loosen the cover screws and remove the air cleaner cover.
2.
Remove the foam filter element from the air cleaner cover.
3.
Remove the air cleaner grid and paper filter element.
4.
Inspect both filter elements, and replace them if they are damaged. Always replace the paper filter element at the scheduled interval (see page ).
7
If the paper filter element is dirty, replace it with a new one. Do not clean the paper filter element.
AIR CLEANER GRID
Squeeze
Soak Oil
6.
Wipe dirt from the inside of the air cleaner case and cover, using
Squeeze
a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor.
7.
Put the air cleaner grid on the paper filter element and install them to the air cleaner case.
8.
Install the foam filter element to the air cleaner cover.
9.
Install the air cleaner cover and tighten the cover screw.
SEDIMENT CUP (applicable types)

Cleaning

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel.
Stop engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.
10
PAPER FILTER ELEMENT
FOAM FILTER ELEMENT
AIR CLEANER COVER
COVER SCREW
1.
Remove the fuel sediment cup, O-ring and filter.
Wash the sediment cup in non-flammable solvent, and dry it
2. thoroughly.
3.
Reinstall the sediment cup. Tighten the sediment cup securely.
ENGLISH
FILTER
O-RING

SEDIMENT CUP

SPARK PLUG

SPARK ARRESTER

Recommended Spark Plugs:
BKR7E-E (NGK) K22PR-UR (DENSO)
The recommended spark plug has the correct heat range for normal engine operating temperatures.
An incorrect spark plug can cause engine damage.
For good performance, the spark plug must be properly gapped and free of deposits.
1.
Remove the nut from the ignition coil, and remove the ignition coil/spark plug cap. Remove any dirt from around the spark plug area.
CLAMP
2.
Remove the spark plug with a
IGNITION COIL/ SPARK PLUG CAP
NUT
SPARK PLUG
SPARK PLUG WRENCH
5/8-inch spark plug wrench.
The spark arrester must be serviced every 6 months or 100 hours to keep it functioning as designed.
If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester.
Spark Arrester Removal (standard types)
1.
Remove the three 6 mm nuts and breather tube from the air cleaner, remove the air cleaner, and remove the 6 20 mm
×
stud bolt.
BREATHER TUBE
AIR CLEANER
620mm
×
STUD BOLT
2.
Remove the three 6 mm bolts from the muffler protector, and
6 mm NUTS
remove the muffler protector.
Removethe5 8mmscrewfromthesparkarrester,and
3.
×
remove the spark arrester from the muffler.
3.
Inspect the spark plug. Replace it if damaged or badly fouled, if the sealing washer is in poor condition, or if the electrode is worn.
4.
Measure the spark plug electrode gap with a wire­type feeler gauge. Correct the gap, if necessary, by carefully
0.70 0.80 mm
(0.028 0.031 in)
SIDE ELECTRODE
bending the side electrode. The gap should be:
0.70 0.80 mm (0.028 0.031 in)
−−
5.
Install the spark plug carefully,
SEALING WASHER
by hand, to avoid cross­threading.
After the spark plug is seated, tighten with a 5/8-inch spark plug
6. wrench to compress the sealing washer.
7.
When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer.
8.
When reinstalling the original spark plug, tighten 1/8 1/4 turn
after the spark plug seats to compress the washer.
6mmBOLTS
5 8 mm SCREW
×
SPARK ARRESTER
A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.
Set the harness in the clamp portion of the ignition coil/spark
9. plug cap. Then, attach the ignition coil to the spark plug and tighten the nut securely.
ENGLISH
11
Spark Arrester Removal (low profile types)
1.
Remove the three 6 mm bolts from the exhaust pipe protector and remove the exhaust pipe protector.
2.
Remove the two 6 mm bolts from the lower shroud and remove the lower shroud.
To make the clearance for 6 mm bolts removing, loosen the
3.
××
6 16 mm bolts, 10 35 mm flange bolt and slide the
muffler stay as shown.
Remove the six 6 mm bolts from the lower muffler protector
4. and remove the lower muffler protector.
Remove the three 6 mm bolts from the muffler protector and
5. slide the muffler protector to upside.
6mmBOLTS
10 35 mm FLANGE BOLT
MUFFLER STAY
616mm
×
BOLT WASHER
×
Remove the 5 8 mm screw from the spark arrester and
6.
×
remove the spark arrester from the muffler.
6mmBOLTS
EXHAUST PIPE PROTECTOR
LOWER SHROUD
6mmBOLTS
Spark Arrester Cleaning & Inspection
Use a brush to remove carbon
1. deposits from the spark arrester screen. Be careful not to damage the screen. Replace the spark arrester if it has breaks or holes. Install the spark arrester to the
2. muffler.
STANDARD TYPES
3.
SCREEN
Install the muffler protector and air cleaner in the reverse order of disassembly.
LOW PROFILE TYPES
Install the exhaust pipe protector, lower shroud, lower muffler protector and muffler in the reverse order of disassembly.

FUSE (applicable types)

If the fuse is blown, the battery cannot be charged.
Fuse change
Removethefusecoverand
1.
FUSE COVER
pull the fuse out. Replace the fuse with a fuse
2. of the same type and rating.
FUSE (3 A)
FUSE (30 A)
12
LOWER MUFFLER PROTECTOR
SPARK ARRESTER
5 8 mm SCREW
×
Never use a fuse with different rating from that specified. Serious damage to the electrical system or fire may result.
Install the fuse cover.
3.
ENGLISH

HELPFUL TIPS & SUGGESTIONS

Engine Oil

STORING YOUR ENGINE

Storage Preparation

Proper storage preparation is essential for keeping your engine trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again.

Cleaning

If the engine has been running, allow it to cool for at least half an hour before cleaning. Clean all exterior surfaces, touch up any damaged paint, and coat other areas that may rust with a light film of oil.
Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening. Water in the air cleaner will soak the air filter, and water that passes through the air filter or muffler can enter the cylinder, causing damage.

Fuel

Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your engine deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced.
1.
Change the engine oil (see page ).
2.
Remove the spark plug (see page ).
3.
Pour a tablespoon 5 10 cm
−−
9
11
(5 10 cc) of clean engine oil into
the cylinder.
4.
With recoil starter types: Pull the starter grip (applicable types) several times to distribute the oil in the cylinder.
Without recoil starter types: Turn the engine switch to the START position to distribute the oil in the cylinder.
5.
Reinstall the spark plug.
6.
With recoil starter types: Pull the starter rope slowly until resistance is felt and the notch on the starter pulley aligns with the projection at the top of the recoil starter cover. This will close the valves so moisture cannot enter the engine cylinder. Return the starter rope gently.
Align the notch on the pulley with the projection at the top of the cover.
The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank.
Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the
Distributor’s Limited Warranty
.
You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.
Adding a Gasoline Stabilizer to Extend Fuel Storage Life
When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage. If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline.
1.
Add gasoline stabilizer following the manufacturer’s instructions.
2.
After adding a gasoline stabilizer, run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor.
3.
Stop the engine.
Without recoil starter types: Remove the nuts and remove the fan cover. Rotate the fin until resistance is felt and the fin with a notch (standard types)/alignment mark (low profile types) aligns with the projection at the top of the cover. This will close the valves so moisture cannot enter the engine cylinder.
STANDARD TYPES
Alignthefinwithanotch with the projection at the top of the cover.
LOW PROFILE TYPES
NUTS
ENGLISH
Align the fin with a alignment mark with the projection at the top of the cover.
13

Draining the Carburetor

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel.
Stop engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.
1.
Place an approved gasoline container below the carburetor, and use a funnel to avoid spilling fuel.
2.
Loosen the carburetor drain screw and drain the gasoline from the carburetor.
If the fuel was drained during storage preparation, fill the tank with fresh gasoline. If you keep a container of gasoline for refueling, be sure it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting.
If the cylinder was coated with oil during storage preparation, the engine will smoke briefly at startup. This is normal.

TRANSPORTING

If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.
Keep the engine level when transporting to reduce the possibility of fuel leakage.

TAKING CARE OF UNEXPECTED PROBLEMS

ELECTRIC STARTER TYPES: Check the LED on the ECM
3.
After all the fuel has drained into the container, tighten the drain screw securely.

Storage Precautions

If your engine will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well-ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark­producing electric motor, or where power tools are operated.
If possible, avoid storage areas with high humidity, because that promotes rust and corrosion.
Keep the engine level in storage. Tilting can cause fuel or oil leakage.
With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the engine, promoting rust and corrosion.
If equipped with a battery for electric starter types, recharge the battery once a month while the engine is in storage. This will help to extend the service life of the battery.

Removal from Storage

Check your engine as described in the
CHECKS
section of this manual (see page ).
BEFORE OPERATION
3
LED ECM
To perform the LED check, the engine must be connected to a battery and the engine switch must be in the ON position.
ENGINE WILL
Possible Cause Correction
NOT START
1.
LED is not lit.
Fuse burnt out.
Replace fuse (p. 12). after replacing fuse, turn the engine switch to the ON position once again.
2.
LED is lit.
Fuel, engine oil, spark plug, etc.
Check the BEFORE OPERATION CHECKS (p. 3).
3.
LED blinks twice.
Engine oil level low.
Fill with the recommended oil to the proper level (p. 8 9).
4.
LED blinks 3 or more times.
ECM, TE sensor, power coil.
Take engine to an authorized Honda servicing dealer, or refer to shop manual.
5.
Take engine to an authorized Honda
ECM, sensors, etc.
Replace or repair faulty components
as necessary. servicing dealer, or refer to shop manual.
14
ENGLISH
ENGINE WILL NOT START
1.
Electric starting (applicable types): Check battery and fuse.
2.
Check control positions.
3.
Check engine oil level.
4.
Check fuel.
5.
Remove and inspect spark plug.
6.
Take engine to an authorized Honda servicing dealer, or refer to shop manual.
Possible Cause Correction
Battery
Recharge battery.
discharged.
Fuse burnt out.
Replace fuse. (p. 12).
Choke open. (Recoil starter types)
Move choke lever to CLOSED position unless the
engine is warm. Engine switch OFF. Engine oil level low.
Turn engine switch
to ON position.
Fill with the
recommended oil
to the proper level
(p. 8 9).
Out of fuel. Bad fuel; engine stored without treating or draining
Refuel (p. 7).
Drain fuel tank and
carburetor (p. 14).
Refuel with fresh
gasoline (p. 7). gasoline, or refueled with bad gasoline. Spark plug faulty, fouled, or
Gap or replace
spark plug (p. 11). improperly gapped. Spark plug wet with fuel (flooded engine).
Dry and reinstall
spark plug. Start
engine with
throttle lever in
MAX. position. Fuel filter restricted, carburetor
Replace or repair
faulty components
as necessary. malfunction, ignition malfunction, valves stuck, etc.

TECHNICAL INFORMATION

TECHNICAL INFORMATION

Serial Number Location

Record the engine serial number, engine type, and date of purchase in the space below. You will need this information when ordering parts and when making technical or warranty inquiries.
SERIAL NUMBER & ENGINE TYPE LOCATION
LOW PROFILE TYPES
Engine serial number: __ __ __ __ __ __ __ __ __ __ __
Engine type: ___ ___ ___ ___
Date Purchased: ______ / ______ / ______
STANDARD TYPES
ELECTRIC STARTER (applicable types)
ELECTRIC STARTER (applicable types)
SERIAL NUMBER & ENGINE TYPE LOCATION

ENGINE LACKS POWER

1.
Check air filter.
2.
Check fuel.
3.
Take engine to an authorized Honda servicing dealer, or refer to shop manual.
Possible Cause Correction
Filter element(s) restricted.
Bad fuel; engine stored without treating or draining
Clean or replace
filter element(s)
(p. 9 10).
Drain fuel tank and
carburetor (p. 14).
Refuel with fresh
gasoline (p. 7). gasoline, or refueled with bad gasoline. Fuel filter restricted, carburetor
Replace or repair
faulty components
as necessary. malfunction, ignition malfunction, valves stuck, etc.
ENGLISH
15

Carburetor Modifications for High Altitude OperationBattery Connections for Electric Starter (applicable types)

Use a 12-volt battery with an ampere-hour rating of at least 18 Ah.
Be careful not to connect the battery in reverse polarity, as this will short circuit the battery charging system. Always connect the positive ( ) battery cable to the battery terminal before connecting the negative ( ) battery cable, so your tools cannot
cause a short circuit if they touch a grounded part while tightening the positive ( ) battery cable end.
A battery can explode if you do not follow the correct procedure, seriously injuring anyone nearby.
Keep all sparks, open flames, and smoking materials away from the battery.
1.
Connect the battery positive ( ) cable to the starter solenoid
terminal as shown.
2.
Connect the battery negative ( ) cable to an engine mounting
bolt, frame bolt, or other good engine ground connection. Connect the battery positive ( ) cable to the battery positive ( )
3.
++
terminal as shown. Connect the battery negative ( ) cable to the battery negative
4. ( ) terminal as shown.
Coat the terminals and cable ends with grease.
5.
At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters (5,000 feet), have your servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.
Even with carburetor modification, engine horsepower will decrease about 3.5% for each 300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.
When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications.
POSITIVE ( ) BATTERY CABLE
NEGATIVE ( ) BATTERY CABLE
16
ENGLISH

Emission Control System Information

Source of Emissions
The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.
The U.S., California Clean Air Acts and Environment Canada
EPA, California and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems.
The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards.
Tampering and Altering
Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are:
Removal or alteration of any part of the intake, fuel, or exhaust systems. Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters.
Replacement Parts
The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California and Canadian emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system.
A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.
Maintenance
Follow the maintenance schedule on page . Remember that this
7 schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or high­temperature operation, or use in unusually wet or dusty conditions, will require more frequent service.

Air Index

An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board.
The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution.
Problems That May Affect Emissions
If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer.
Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
The durability description is intended to provide you with information relating to the engine’s emission durability period. The descriptive term indicates the useful life period for the engine’s emission control system. See your
Warranty
for additional information.
Emission Control System
Descriptive Term Applicable to Emissions Durability Period
Moderate 50 hours [0 80 cm
125 hours [greater than 80 cm
Intermediate 125 hours [0 80 cm
250 hours [greater than 80 cm
Extended 300 hours [0 80 cm
500 hours [greater than 80 cm
−−
(0 80 cc) inclusive]
(80 cc)]
−−
(0 80 cc) inclusive]
(80 cc)]
−−
(0 80 cc) inclusive]
(80 cc)]
The Air Index Information hang tag/label must remain on the engine until it is sold. Remove the hang tag before operating the engine.
ENGLISH
17
Specifications (standard types) Tuneup Specifications
ITEM SPECIFICATION MAINTENANCE
PTO shaft type S
Length Width
××
Height Dry mass [weight] Engine type
Displacement [Bore Stroke]
×
Net power
(in accordance with SAE J1349 )
Max. Net torque
(in accordance with SAE J1349 )
Engine oil capacity Fuel tank capacity Cooling system Ignition system PTO shaft rotation
407 505 454 mm
××
(16.0 19.9 17.9 in)
××
39.4 kg (86.9 lbs)
4-stroke, overhead camshaft, single
cylinder
438 cm
××
[88.0 72.1 mm (3.46 2.84 in)]
(26.7 cu-in)
9.5 kW (12.9 PS, 12.7 bhp)
at 3,600 rpm
29.8 N·m (3.04 kgf·m, 22.0 lbf·ft)
1.1
5.9
at 2,500 rpm
(1.2 US qt , 1.0 Imp qt)
(1.56 US gal , 1.30 Imp gal)
Forced air
CDI type magneto ignition
Counterclockwise
Spark plug gap
Valve clearance (cold)
Other specifications
Specifications (low profile types)
PTO shaft type V
Length Width Height Dry mass [weight] Engine type
××
××
553 553 346 mm
××
(21.8 21.8 13.6 in)
42.8 kg (94.4 lbs)
4-stroke, overhead camshaft, single
cylinder Displacement [Bore Stroke]
×
Net power
(in accordance with SAE J1349 )
Max. Net torque
(in accordance with SAE J1349 )
Engine oil capacity Cooling system Ignition system PTO shaft rotation
438 cm
××
[88.0 72.1 mm (3.46 2.84 in)]
(26.7 cu-in)
9.5 kW (12.9 PS, 12.7 bhp) at 3,600 rpm
29.8 N·m (3.04 kgf·m, 22.0 lbf·ft) at 2,500 rpm
1.1
(1.2 US qt , 1.0 Imp qt)
Forced air
CDI type magneto ignition
Counterclockwise
0.70 0.80 mm
(0.028 0.031 in)
IN: 0.12 0.02 mm EX: 0.15 0.02 mm
±
±
No other adjustments needed.
Refer to page: 11
See your authorized Honda dealer
The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass production engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.
18
ENGLISH

Quick Reference Information

Fuel
Engine oil
Unleaded gasoline (Refer to page 7)
U.S. Except U.S.
Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 86 or higher
SAE 10W-30, API SJ or later, for general use.
Refer to page 8.
Spark plug
BKR7E-E (NGK) K22PR-UR (DENSO)
Maintenance
Before each use:
Check engine oil level. Refer to page 8. Check air filter. Refer to page 9 10.
First 20 hours:
Change engine oil. Refer to page 9.
Subsequent:
Refer to the maintenance schedule on page 7.
Muffler Deflector Kit Installation (standard types)
Muffler deflector (applicable types)
Turn the outlet of the muffler deflector downward and tighten the three 4 6 mm screws securely.
×

Wiring Diagrams

1
FUSE 3 A
[]
2
FUSE 30 A
[]
3
FUEL CUT SOLENOID
[]
RECTIFIER
4
REGULATOR RECTIFIER
[]
5
ENGINE GROUND
[]
6
BATTERY
[]
7
STARTER MOTOR
[]
8
POWER COIL
[]
9
FUEL CUT SOLENOID COIL
[]
10
CHARGE COIL 20 A
[]
11
CHARGE COIL 3 A
[]
12
CRANKSHAFT POSITION
[]
(CKP) SENSOR
Bl
Black
Y
Yellow
Bu
Blue
G
Green
R
Red
W
White
Br
O Lb Lg
P Gr
13
[]
14
[]
15
[]
16
[]
17
[]
18
[]
19
[]
20
[]
21
[]
22
[]
23
[]
24
[]
25
[]
Brown Orange Light blue Light green Pink Gray
FUEL CUT SOLENOID IGINITION COIL SPARK PLUG OIL LEVEL SWITCH ECM STEP MOTOR (GOV) STEP MOTOR (CHOKE) PC CONNECTOR ENGINE TEMPERATURE SENSOR THROTTLE CONTROL COMBINATION SWITCH RECTIFIER ENGINE STOP SWITCH
ATTACHMENT POSITION
×
4 6 mm SCREWS
MUFFLER DEFLECTOR
ENGLISH
19
ELECTRIC STARTER TYPES (20 A)
20
ENGLISH
ELECTRIC STARTER TYPES (3 A)
ENGLISH
21
RECOIL STARTER TYPES
22
ENGLISH
Loading...
+ 50 hidden pages